Apparatus for milling a surface

ABSTRACT

The present invention provides an apparatus for use on a roof or the like which incorporates an insulation material. The invention allows workers to shave the insulating layer to smooth, remove high spots, or create slopes, valleys or sumps, in order to achieve positive slope for water drainage. As part of the invention, there is provided, an apparatus for milling the surface of a low slope substrate, comprising a milling device comprising a cylindrical tubular structure having an outer rotatable milling surface, said surface positionable adjacent said substrate and drivable in a rotary motion to mill the surface of the substrate; a milling device support upon which said milling device is mounted for movement in a milling direction; a mounting assembly for mounting said milling device to said support; said mounting assembly including means for adjusting the angle and depth of engagement of said milling surface to said substrate.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to a Canadian Application filed on Apr.28, 2006, entitled Improved Apparatus for Milling a Surface, theapplication number of which has yet to be assigned, which is entirelyincorporated herein by reference.

FIELD OF THE INVENTION

The invention is an apparatus for milling the surface of essentially lowslope substrate. The invention is particularly useful for levelling arigid insulation material applied to a roof during the process of roofconstruction.

Low slope roofs for buildings are typically comprised of a deck (oroptionally a vapour barrier), a layer of insulation, or insulating fill,a waterproof membrane, and an exterior finish material. In order toavoid the ponding of water on the finished roof, the roof deck orinsulation material is typically sloped to provide positive drainage.Often roofs are constructed without slope or include inadequate slope.Thus, positive slope often is not achieved.

SUMMARY OF THE INVENTION

The present invention provides an apparatus for use preferably on a roofor the like which incorporates an insulation material. The inventionallows workers to shave the insulating layer to remove high spots, orcreate slopes, valleys or sumps, in order to achieve positive slope forwater drainage. It should be understood that the invention may also beutilized on other substantially flat surfaces to smooth, remove highspots, create valleys, slopes and the like.

In accordance with an aspect of the invention, there is provided anapparatus for milling the surface of a low slope substrate, comprising:a milling device comprising a cylindrical tubular structure having anouter rotatable milling surface, positionable adjacent said substrateand which may be driven in a rotary motion to mill the surface of thesubstrate; a track positioned above said substrate along which themilling device is mounted in a position adjacent said substrate; amounting assembly for mounting the milling device to the track, themounting assembly including means for engaging the track and enablingmovement of the assembly along the track in a milling direction, themilling device supported in rotatable engagement from the mountingassembly such that the milling surface engages the substrate for millingthereof, the mounting assembly including adjustment means for adjustingthe angle and depth of the outer milling surface relative to thesubstrate to allow for variation in the depth and angle to be milled onthe substrate.

In accordance with a further aspect of the invention there is provided,an apparatus for milling the surface of a low slope substrate,comprising a milling device comprising a cylindrical tubular structurehaving an outer rotatable milling surface, said surface positionableadjacent said substrate and drivable in a rotary motion to mill thesurface of the substrate; a milling device support upon which saidmilling device is mounted for movement in a milling direction; amounting assembly for mounting said milling device to said support; saidmounting assembly including means for adjusting the angle and depth ofengagement of said milling surface to said substrate.

Other objects, features and advantages of the present invention will beapparent from the following non-restrictive description of exampleembodiments of the invention, made with reference to the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a front elevational view of an embodiment of the invention;

FIG. 1A is a front elevational view of an alternate embodiment of theinvention illustrating supports for the track having wheels thereon;

FIG. 2 is a rear elevational view of the embodiment of FIG. 1 of theinvention;

FIG. 3 is a side elevational view of the embodiment of FIG. 1 of theinvention;

FIG. 4 is a perspective view of an embodiment of a mounting assembly inaccordance with an aspect of the invention;

FIG. 4A is perspective view of an alternate embodiment of the millingdevice and lower frame of the mounting assembly illustrating a vacuumattachment thereto;

FIG. 5 is a bottom front elevation perspective view of an embodiment ofthe milling device mounted to the lower frame of the mounting assemblywith outer portions of the lower frame not illustrate to best showfeatures of the apparatus;

FIG. 5A is an illustration of a portion of an embodiment of the millingdevice illustrating saw chain wrapped around outer circumferencethereof;

FIG. 6 is a top plan view of the track and top plate of the mountingassembly of the apparatus;

FIG. 7 is a plan view showing the rotatable connection of the top andbottom plates of the mounting assembly; and

FIG. 8 is a detailed view of an embodiment of the means for attachmentof the cross support members of the track to the upright members andmeans to adjust the support members relative to the plane of the track.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS OF THE INVENTION

The invention will be described in relation to its use as an apparatusfor leveling an insulating material installed on a roof or otherstructure or for the purpose of leveling or providing a slope. Theapparatus can be used in new or retrofit construction type projects asto either level or slope a surface.

In the example embodiment shown in the figures, milling is accomplishedby a rotatable cylindrical milling device 100 having an outer millingsurface 102. In the embodiment shown, the outer milling surfacecomprises a plurality of rows of cutting teeth 104 on the outercircumferential surface thereof. Such teeth are preferably provided by acutting chain 88, secured about the outer circumference, aligned in saidplurality of rows. Shown schematically in FIGS. 1 and 2, teeth 104 inadjacent rows around the circumference of the milling device are alignedoffset to each other and are aligned on a slight angle to the verticalplane V. The circumference and length of the device will vary dependingon the desired depth of insulation to be removed.

As the device is rotated about its axis (defined by line A-A), driven bya motor 106, as will be discussed below, the device is brought intoengagement with a substrate S at a selected slope angle and depth formilling a desired slope onto a roof or the like, and is moved alongtrack 12 to define a milling run. The details of the track 12 andsupport structure 21 for the track are set out below. The milling devicecan be moved along the milling run by pulling, pushing, by a motorizedgear or hydraulic cable device or any other known manner.

As best seen in FIG. 5 which is an illustration in isolation of anexample milling device attached to the lower frame 110, an axle 109extends through the rotational axis (A-A) of the milling device 100,extending outwardly from opposite sides 100 a, 100 b of the millingdevice. The milling device 100 is rotatably mounted to lower frame 110as follows. The axle 109 protruding at each end is supported by an axlesupport 112, which is mounted on the top wall 135 of the lower frame ateach end of the device 100. The lower frame 110 comprises top 135, rear136, front 138 and side walls 140 bolted together, which surround anupper portion of the milling device, leaving a lower portion of themilling device to engage substrate S. A downwardly angled backwardextension splash wall 143 extends rearwardly from the top 135 and rearwall 136 to prevent spraying of discharge of milled material upwardly atthe front of the device 100. The extension wall 143 includes adownwardly oriented adjustable containment skirt 145, preferablycomprised of rubber or metal, attached to the rear edge thereof whichaids in the prevention of upward spraying of the milled material. Itshould be understood that the containment skirt may extend around rear136, front 138 and side walls 140 if desired, such as is shown in FIG.4A.

As can be seen in FIG. 4A, the lower frame may include a vacuumattachment 220 piece, formed as part of splash wall 143, having an inlet220A communicating within the lower frame, adjacent the milling device.A vacuum hose may be attached to the inlet 220A which would allow forremoval of milled material by vacuum means connected to said hose.

As can be seen in FIG. 5, the device 100 is rotated about axis A-A bydrive means 116, which in the embodiment shown, is provided by a motor106 mounted on the top wall 135 of lower frame 110, operativelyconnected to the milling device by means of a drive belt 118 whichengages a drive end portion 119 of the axle, and rotates the deviceabout its axis A-A. Drive belt and pulley for the motor are enclosed byprotective covers 155.

The lower frame 100 is connected to an upper mounting assembly 101 bymeans of a pair of vertically adjustable legs 111 positioned at each endof the milling device. The legs are mounted to the lower frame each by amounting bracket 114. In the example shown, each mounting bracket 114 isbolted to the front 136 and rear wall 138 of the frame. In the exampleshown, the legs 111 are mounted to an upper frame member 116 of theupper mounting assembly 120 which itself is attached to bottom plate 45of the upper mounting assembly 120. The bottom plate 45 is mounted to anupper plate 39 in a manner described in detail below. To adjust theslope angle and depth of the milling device against substrate S,relative vertical alignment of the device may be achieved byelectronically activated height adjustment of the vertical legs 111. Thevertical legs 111 illustrated are of a retractable-extendabletelescoping piston-type, however it should be understood that anysuitable expandable and retractable leg form may be utilized. Electronicactivation is provided by an electronic controller 122 which activatesan extendable-retractable piston on each leg 111 to adjust the verticalheight thereof. Control means is provided by an electronic control boxsystem 122 connected to each leg by electronic wiring or the like, theuser activation portion of which is preferably detachably mountable onthe lower frame. Control may also be provided by wireless remotecontrol. It should be understood that in accordance with a furtheraspect of the invention, the vertical adjustment of the legs may beachieved manually in any known manner, such as for example by hydraulicadjustable piston, or mechanically such as with a retractabletelescoping post in a mating sleeve each having a plurality of matingholes into which a locking pin may be inserted to secure the post suchthat it extends from the sleeve at varying lengths.

Preferably, a vertical stabilizer bar 130 is mounted between uppermounting assembly (in the example mounted to upper frame member 116 ofthe upper mounting assembly 120) and the lower frame 110, preferablymounted to the front wall 138 at a central location between oppositeends 100 a and 100 b of the milling device 100. While one bar is shown,the device may include more than one bar. Other stabilizing devicescould be utilized to connect the upper and lower frame if desired.

The stabilizer bar 130 is mounted to each of the upper frame member 116and front wall 138 of lower frame by means of vertically orientedbracket 140, secured thereto, the bracket 140 sized to allow selectivesliding engagement of the bar 130 relative to the upper frame member 116and the lower frame 110.

Once slope angle and depth is adjusted by relative vertical adjustmentof vertical legs 111, the stabilizer bar 130 is tightened into lockingengagement in each bracket 140, preferably by quick locking means 142.In the example shown, quick locking means 142 is provided by a wing nut,which is threadably engaged in an opening 144 in the bracket and may beadvanced until engaging the stabilizer bar 130 to securely fasten it inposition within the bracket. Any suitable quick locking means may beprovided, such as a through pin or bolt or the like. Once secured inplace, the stabilizer bar 130 is designed to provide additionalstability to the apparatus, necessitated by grinding forces from themilling device of this embodiment as it is pulled along the milling run.

In the embodiment shown, as the milling device operates along themilling run against a substrate S, and is moved along the track 12,forces from engagement of the milling device as it rotates against thesubstrate S, in part caused by the slight angle of the milling teeth 104rows, tend to pull the device laterally to the direction of rotation ofthe device 100 as it is advanced along the guide track 12. In theillustration shown in FIG. 1, as the milling device 100 travels alongthe milling track 12 defining a milling run, the device tends to pull tothe left (in the direction of the angle of the rows of teeth to thevertical). The stabilizer bar 130, once fastened securely into eachbracket 140, by quick locking means 142, such as a wing nut or the like,acts to resist such lateral pulling forces.

Preferably, the operator of the machine moves the device along the trackdefining a milling run, for example by means of a cable (not shown)attached to the stabilizer bar 130. The milling device can be drivenalong the milling run by manual pulling, manual pushing, by a motorizedgear, electronic, air or hydraulic motor or any other known manner.

In the example shown, the milling device rotates in the directionopposite to the direction of travel of the milling device (i.e. in thedirection of arrow Q in FIG. 3).

In an example of a milling run, the operator moves the device alongtrack in a direction in a forward motion, with the device oriented indirection D. The depth and angle of the milling device may be adjustedas the device moves along the milling run by height adjustable verticallegs 120. As the device gets to end of run in direction A, the device isrotated about axis C-C, 180 degrees and is fixed in place by rod 551,then the device is moved back in the opposite direction to D, parallelthereto, creating a milled path adjacent and partially overlapping theinitial run in direction D. By adjusting the depth and angle as thedevice is pulled along this adjacent run, the desired slope or trough orleveling may be formed. In the example embodiments shown, the millingdevice can mill from 1/16 inches to 4 inches or more in a single pass.

Further embodiments of aspects of the invention are described asfollows: The apparatus 10 comprises a track, such as a ladder 12 alongwhich the milling device 100 may move. The track 12 with two parallelrails 16 and 17 along which are spaced a plurality of rungs 18, whichpreferably are tubes extending through the rails 16 and 17. The track 12total assembly is supported above the substrate roof insulation by meansof a plurality of adjustable support structures 21, which compriseupright members 22, each being supported by a base 23, and a crossmember 24 which is sized to extend through a tubular rung 18 of thetrack 12 and be slidably height adjustable along the upright members 22.

As best seen in FIGS. 1 and 8, an example apparatus for facilitating theassembly of the track (such as ladder 12) and cross member 24 andupright members 22 is shown. Cross member 24 is threadably engagedwithin a horizontally oriented sleeve 171 defining an opening in anattachment piece 160. Upper portions 22U of the upright members 22 arethreadably engagable in a vertically oriented sleeve 162 in theattachment piece. Vertical sleeves 162 of attachment piece 160 arethreaded along the upper portion of upright members 22U to allowvertical adjustment of the track. Each sleeve 162 is equipped with alocking means for securing the sleeve 162 in place along the uprightmember 22. A preferred locking means is at least one adjustable nut 27positioned adjacent the sleeve 162 for selectively engaging the uprightmember 22 to secure the upright member in place in vertical sleeve bybringing the nut 27 into threaded engagement with the upper threadedportion 22U of the upright member and engagement against the sleeve 162.The nut is brought into threaded engagement with portion 22U by rotatingsame by means of handle 167. In addition to the height adjustmentprovided by vertically adjustable legs described above, the apparatusmay also be adjusted by adjusting the angle of the track 12 itself byadjusting the relative height of the cross member 24 on the uprightmembers 22.

In the embodiment shown, the upright member 22 is hinged to the base 23and is securable at an angle to the base 23 by means of a bolt 30 andnut 31. This hinged relationship allows the base 23 to be oriented andprovide support along the slope of a roof surface with the uprightmember 22 vertical.

In an alternate embodiment shown in FIG. 1A, the support members 22 aresupported on wheels 250, which are selectively lockable in fixedpositions to ensure that once a position is chosen the apparatus doesnot move. This allows the entire apparatus to be moved easily intodesired positions on a construction site where site sloping or levelingis required to allow commencement of milling runs.

In a further alternate embodiment, not shown, but contemplated by anaspect of the invention, the milling device is carried by a mountingunit having a plurality of support wheels positioned outside of themilling device. Positioning of the wheels outside of the milling deviceallows the milling device to be rotated about vertical axis C. Themilling device may be mounted to hang from the mounting unit in asimilar manner as discussed above, to allow for adjustment of depth andangle of slope (i.e. for example with upper and lower frames connectedby vertically adjustable legs). It could be mounted by other suitablemeans. However, the milling device does not move along a track in thisembodiment, rather, it is fixed to the mounting unit and the mountingunit itself moves along the milling run itself, along its wheels.Preferably this mounting unit has 4 wheels positioned at outer cornersof the unit. This allows easy transport and relocation of the device tovarious sites on a roof.

An example method for facilitating the assembly of the track 12 andsupport structures 21 is as follows. The cross members 24 aredisassembled from the upright members 22, and a sleeve 171 is unscrewedfrom one end. The free ends of the cross members 24 are passed throughrungs 18 and then reattached to the threaded sleeve 171 of attachmentpiece 160. The cross members 24 are spaced along the track 12sufficiently close to one another to provide adequate support andstability to the apparatus as fully assembled. Typically, the crossmembers 24 are spaced 3 to 5 feet apart. Each rung 18 has a bolt 32threaded through it for engaging and securing the cross member 24 to therung 18. The track 12 having the cross members 24 extending throughrungs 18 is then suspended above the substrate such as roof insulationby affixing each cross member 24 to a pair of upright members 22. Theslope angle of the track 12 can be set at this stage of the assembly ofthe apparatus. However, it may also be achieved to allow such adjustmentby means of adjustable vertical legs 111, in the manner discussed above.

In the example shown, and as discussed above, the milling device 100 issuspended from the elevated track 12 by mounting assembly, which asdiscussed above comprises upper mounting assembly 120 attached to lowerframe 110 by means of vertically adjustable legs 111, In the embodimentshown, the upper mounting assembly 120 comprises rail engaging rollers37 each of which is mounted on a shaft 38 fixed in a top plate 39 (seenin FIGS. 6 and 7). Preferably, each roller 37 is provided with a rollerbearing 41. In the embodiment shown, four rollers 37 are mounted in thetop plate 39 with two rollers 37 engaging the rail 16 and two rollers 37engaging the rail 17, but the skilled person will appreciate that otherarrangements may be better suited for use in association with differentmilling devices. Also, a frame or similar structure may be used insteadof the plate 39 in some circumstances. In the present embodiment, theplate 39 is preferred to facilitate the desired orientation of themilling device 100. Thus, the top plate 39 is attached to a bottom plate45 by means of a shaft and roller bearing assembly 47 bolted to eachplate 39 and 45. The roller bearing assembly 47 allows the bottom plate45 to be rotated relative to the top plate 39. This rotationalcapability is facilitated by rollers 48 affixed to the bottom plate 45and engaging the top plate 39. To provide stability and ensure properalignment of the milling device a spacer 51 is positioned between thetop and bottom plates, extending around the outer circumference of theplates. This spacer which could be a continuous circumferential piece 51or a plurality of regularly spaced apart pieces extending around thecircumference. The spacer is particularly important to provide properalignment and stability and to prevent tipping of the device, given thatin the preferred embodiment such as shown in FIG. 1, the milling deviceis offset from the vertical rotational axis of the device (Axis C inFIG. 1). It should be understood that milling device may or may not beoffset from vertical axis C. The rotational orientation of the top plate39 to the bottom plate 45 may be fixed by means of a spring loaded rod551 attached to the bottom plate 45 and being extendable through any ofa plurality of holes 53 formed through the top plate 39 in a circulararray.

It is to be understood that while but several embodiments of the presentinvention have been herein shown and described, it will be understoodthat various changes in size and shape of parts may be made. It will beevident that these modifications, and others which may be obvious topersons of ordinary skill in the art, may be made without departing fromthe spirit or scope of the invention, which is accordingly limited onlyby the claims appended hereto, purposively construed.

1. An apparatus for milling the surface of a low slope substrate,comprising: a milling device comprising a cylindrical tubular structurehaving an outer rotatable milling surface, positionable adjacent saidsubstrate and which may be driven in a rotary motion to mill the surfaceof the substrate; a track positioned above said substrate along whichthe milling device is mounted in a position adjacent said substrate; amounting assembly for mounting the milling device to the track, themounting assembly including means for engaging the track and enablingmovement of the assembly along the track in a milling direction, themilling device supported in rotatable engagement from the mountingassembly such that the milling surface engages the substrate for millingthereof, the mounting assembly including adjustment means for adjustingthe angle and depth of the outer milling surface relative to thesubstrate to allow for variation in the depth and angle to be milled onthe substrate.
 2. The apparatus as recited in claim 1 wherein said outermilling surface comprises a plurality of rows of cutting teeth extendingoutwardly therefrom around the outer circumferential surface thereof. 3.The apparatus as recited in claim 1 wherein said surface is formed froma saw chain including a plurality of teeth, wrapped around said outersurface such that the teeth are oriented in said rows.
 4. The apparatusas recited in claim 3 wherein said teeth are aligned in rows positionedat an angle to direction of rotation of the cylindrical device.
 5. Theapparatus as recited In claim 1 wherein the mounting assembly includesan upper mounting assembly which includes said means for engaging saidtrack, said mounting assembly further including a lower frame upon whichsaid milling device is rotatably mounted, said lower frame beingconnected to the upper mounting assembly by at least two verticallyadjustable legs.
 6. The apparatus as recited in claim 5 wherein saidupper mounting assembly includes a top plate having a plurality of railengaging rollers for engaging the track.
 7. The apparatus as recited inclaim 6 wherein the upper mounting assembly comprises a bottom platerotatably attached to the top plate, and the top and bottom plates beingrotatably attached to one another by a shaft and roller bearing assemblyaffixed centrally to each plate.
 8. The apparatus as recited in claim 5wherein said vertically adjustable legs are adjustable by electroniccontrol means to extend or retract, thereby allowing adjustment of thedepth and angle of the milling device against the substrate for milling.9. The apparatus as recited in claim 7 wherein an upper frame member isattached to the bottom surface of said lower plate, and said verticallyadjustable legs are mounted to said upper frame member.
 10. Theapparatus as recited in claim 8 wherein said electronic control means isprovided by an electronic control box operatively connected to each legfor vertical adjustment, said control box being detachably mountable onsaid mounting assembly.
 11. The apparatus as recited in claim 1 whereinsaid milling device is driven in said rotary motion by means of a motormounted on said mounting assembly operatively connected to the millingdevice by means of a drive belt which engages said milling device androtates the device such that the outer milling surface mills thesubstrate.
 12. The apparatus as recited in claim 5 wherein said millingdevice includes an axle extending through the rotational axis of themilling device, extending outwardly from opposite sides of the millingdevice and said drive means comprises a motor mounted on the lowerframe, operatively connected to the milling device by means of a drivebelt which engages a drive end of said axle, and rotates the deviceabout said axis.
 13. The apparatus as 10 wherein said milling device isrotatably mounted to said lower frame at each end thereof by means byaxle supports, which each carry a portion of the axle extendingoutwardly from said opposite ends of the milling device.
 14. Theapparatus as recited in claim 5 wherein at least one vertical stabilizerbar is mounted between the upper mounting assembly and the lower frame.15. The apparatus as recited in claim 12, wherein said at least onevertical stabilizer bar is mounted to each of the upper mountingassembly and lower frames by means of vertically oriented bracket, eachbracket allowing selective sliding engagement of the bar relative to theupper mounting assembly and the lower frame to allow for adjustment oflength of vertically adjustable legs.
 16. The apparatus as recited inclaim 13 wherein the stabilizer bar is tightenable into lockingengagement in each bracket by quick locking means.
 17. The apparatus asclaimed in claim 1, wherein the means for engaging the track comprisesfour of said rail engaging rollers, each of which is mounted on a shaftfixed in the top plate of the mounting assembly, each of said railsbeing engaged by two said rail engaging rollers.
 18. The apparatus asclaimed in claim 1, further comprising a plurality of rollers affixed tothe bottom plate and engaging the top plate.
 19. The apparatus asclaimed in claim 7, wherein a spacer is positioned between said topplate and bottom plate, positioned adjacent the outer circumference ofsaid plates so as to stabilize the apparatus as bottom plate rotatesrelative to said top plate.
 20. The apparatus as recited in claim 19wherein the top plate has a plurality of holes through it in a circulararray, and a spring loaded rod is attached to the bottom plate and isextendable through any of said holes in the top plate, thereby fixing arotational orientation of the bottom plate relative to the top plate.21. The apparatus as recited in claim 1 wherein the track is supportedabove the substrate by a plurality of supports, each having adjustmentmeans for orienting the track horizontally or at a desired angle tohorizontal above the substrate
 22. An apparatus as recited in claim 1wherein said track comprising a pair of parallel rails along which arespaced a plurality of rungs, said rails and said rungs forming a ladderstructure.
 23. Apparatus as recited in claim 5 wherein said lower framecomprises top, front, rear and side walls which surround an upperportion of the milling device, leaving a lower portion of the millingdevice exposed to engage said substrate, said walls oriented so as toprevent discharge of milled material except below the rear wall of themilling device.
 24. Apparatus as recited in claim 5 wherein said lowerframe further includes a vacuum attachment having a vacuum inletpositioned adjacent said milling device for gathering discharged milledmaterial from the substrate.
 25. An apparatus for milling the surface ofa low slope substrate, comprising: a milling device comprising acylindrical tubular structure having an outer rotatable milling surface,said surface positionable adjacent said substrate and drivable in arotary motion to mill the surface of the substrate; a milling devicesupport upon which said milling device is mounted for movement in amilling direction; a mounting assembly for mounting said milling deviceto said support; said mounting assembly including means for adjustingthe angle and depth of engagement of said milling surface to saidsubstrate.